The PMC welding process: stable ignition and minimal spattering

PMC welding process - faster, more economical welding

PMC welding process video

With its optimized pulse characteristics, Pulse Multi Control provides high-quality welds at high welding speeds. With penetration stabilizer and arc length stabilizer, gaining control over the arc has never been easier.

PMC represents a further development to the pulsed arc, including its stabilizers. The modified process is characterized by precisely regulated and low-spatter droplet detachment. At the same time, PMC generates a powerful and stable arc, which facilitates perfect control of the weld pool. Irregularities during welding—such as undercuts—are thereby avoided, while the welding results are always reproducible and stable.

The benefits for you

Optimized pulsed arc

/ Enhanced process stability from precision adjustment control

/ Spatter-free ignition (SFI)

/ Improved pulse shape

Improved weld properties

/ 15% higher welding speed*

/ 15% less energy input*

/ Consistent penetration

High weld seam quality and appearance

/ Optimized welding of vertical-upseams thanks to the “PMC Mix” characteristic

/ 100% control with arc length and penetration stabilizer

/ TIG-like seam rippling thanks to PMC Ripple Drive

* Compared to a conventional pulsed arc.

Stable ignition and minimal spattering

Spatter-free ignition (SFI)

SFI ignition causes a retraction movement of the wire electrode at a low current level; this results in a guaranteed stable and reproducible start to welding.

Furthermore, SFI HotStart with increased arc energy in the ignition process reduces the risk of fusion defects—in particular with aluminum.

Manual welding with PMC

Weld vertical-up seams at top speed without oscillating motion

The PMC Welding Package includes several characteristics, meaning you enjoy a range of benefits. We offer the optimal support you need for perfect seams in every application. For example, PMC Mix is for vertical-up seams and allows up to 40% higher speeds because oscillating motion is eliminated.

Package contains:

Universal
Arc Blow
Dynamic
Mix
PCS

Universal

Universally applicable characteristics

It can be used for the majority of welds regardless of the weld seam profile or position.

Arc Blow

Arc stability against arc blow

Improved properties against arc break—due to arc blow caused by external magnetic fields.

Dynamic

High arc pressure with small arc focus

These properties are possible thanks to the combination of high current and low voltage. This makes the characteristic ideal for narrow welds with a small opening angle, while it is also perfect for applications that require high welding speeds and a high degree of penetration.

Mix

Ideal when it comes to welding vertical-up seams

This characteristic enables high welding speeds compared to a conventional dip transfer arc, because oscillation motions are eliminated. This is achieved by combining a PMC and LSC dip transfer arc.

PCS (Pulse Controlled Spray Arc)

Combines the advantages of pulsed and spray arcs in a single characteristic

The PCS characteristic improves results, particularly with applications involving small gaps, fillet welds, and root passes.

Robotic welding with PMC

There are a range of requirements for robotic welding

No matter whether the objective is higher welding speeds, the perfect seam appearance, or reproducible quality—Pulse Multi Controlfully satisfies all these requirements. The result is a package of different characteristics that is perfectly tailored to the customer’s requirements.

90% fewer ignition failures thanks to SlagHammer*

Cleaner and safer start to the welding process: Silicate islands that have been deposited on the seam surface from previous welds are knocked off by the reversing wire movement during the ignition process.

Package contains:

Braze
Multi Arc
Cladding
Galvanized
Mix Drive
Ripple Drive

*according to customer calculations

Comparison of Welding Packages

– TPS 500i

– MTB 500i W R

– WF 25i

– For CMT comparison: additional reel, SB60, Robacta Drive

– 7° torch contact angle, with slight push and at 15° relative to the workpiece and welding table in 30° PG position

– Filler metal: G3Si1 (1.2 mm diameter)

– Shielding gas: M21 (18% Ar + 82% CO2, 12 l/min)

– Parent material: 2 mm ground steel plate

Braze

Characteristic for MIG/MAG brazing

High brazing speed, reliable wetting, and good flow of braze material

Multi Arc

Influence of several arcs

Improved properties when a component is being welded by several arcs that influence one another

Cladding

Characteristic for overlay welding

With low penetration, low dilution, and wide weld seam flow

Galvanized

Welding galvanized sheets in a safe and reproducible manner

Lower risk of zinc porosity and reduced zinc burn-off

Mix Drive

Good gap-bridging ability

Process change between PMC and dip transfer arc, combined with a reversing wire movement for high welding speeds.

Ripple Drive

Seam appearance at TIG level

The PMC characteristic for visually impressive seams. The result is elegant seam jointing with a TIG aesthetic. However, the speed is significantly higher than with TIG—thanks to the optimally coordinated pulse process, combined with defined pause times.

PMC AC*

Reverse polarity of the wire electrode

Optimal for welding thin or ultra-light gage sheet joints: the PMC AC process enables remarkably low heat input at a constant deposition rate. The special thing about this technology is that the positive and negative component can be easily adjusted with the help of correction parameters. The result is precise control over the heat input.

The benefits:

/ Low heat input

/ Excellent gap-bridging ability

/ Easy arc handling for manual and automated welding

/ Gleaming welds due to reduced magnesium oxides (for AlMg wires)

/ Lower welding fume emissions

* PMC AC is available on the iWave AC/DC with Multiprocess Pro.

More about iWave Multiprocess PRO

Penetration and arc length stabilizer

It’s all about the wire speed

Supported in different applications: it compensates for stickout changes, paving the way for an almost constant level of weld seam quality.

With an activated penetration stabilizer, the system readjusts the wire speed rather than the welding current. This results in constant penetration. An additional wire control keeps the current and penetration constant if the distance between the welding torch and the component changes. As a result, the arc becomes much more stable, while penetration always remains the same.

The benefits:

/ Improved welding quality

/ Savings in rework and costs

/ Ideal support in case of insufficient visibility or accessibility = stickout fluctuations are automatically compensated for

/ Ideal for position welding

/ Narrower opening angles can be used, saving on filler material

Arc length stabilizer

for a constant arc length

Automatically compensate for irregularities— the arc length is kept constant regardless of the welding voltage. This results in the seam quality remaining unchanged even if the torch position changes or the component tolerances vary.

Optimum support for the following circumstances:

/ Dynamic, changing position of the torch

/ Component tolerances: changing sheet thicknesses or gaps

/ Irregular heat dissipation

/ Changes in speed

The benefits:

/ No need for the welding operation to be interrupted or for manual readjustment of the arc length when the torch position changes

/ Reduced risk of undercuts

/ Quick determination of parameters

/ Focused arc

/ Higher welding speeds

More process technologies

CMT welding process

LSC welding process

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